Methods for grouting tile

ABSTRACT

An improved method for grouting tile which comprises applying a property-improving material subsequent to trowelling of the grouting composition so as to advantageously modify the working properties and/or final performance properties of the grout initially used and supplied in the container.

ite States Patent ernett 1 May 29, 1973 METHODS FOR GROUTING TILE 2,853,928 9/1958 Reardon.... ....264/79 3,140,566 7/1964 Wagner ..52/744 [75] Invent Yardley 3,381,066 4/1968 Lowe ..264/261 [73] Assignee: Tile Council of America, Inc., New

York, N.Y. Primary Examiner-John E. Murtagh [22] Filed: Mar. 31 1971 Attorney-Morgan, Finnegan, Durham & Pine [21] Appl. No.: 130,006 [57] ABSTRACT An improved method for grouting tile which com- [52] US. Cl ..52/744, 52/309 prises applying a property-improving material sub- [51] Em. C]. ..E04f 13/00 sequent to trowelling of the grouting composition so [58] Field of Search ..52/744, 309, 315, as to advantageously modify the working properties 52/3 /133, 79, 256, 261 and/or final performance properties of the grout initially used and supplied in the container. [56] References Cited 6 Claims, No Drawings UNITED STATES PATENTS 1,73l,l62 10/1929 Ficklen ..52/744 METHODS FOR GROUTING TILE BACKGROUND OF THE INVENTION This invention relates to an improved method of grouting tile. More particularly, it relates to the process of applying a material to an already trowelled tile grout in order to impart properties different than those of the original grouting composition.

Formulation of a new ceramic tile grout is a difficult, time consuming operation that more than not ends in practical failure. Although there now exists numerous acceptable grouting compositions, the ultimate test is not simply the observance of good performance properties. A formulation must be packagable in relatively small containers (up to 5 gallons); it must have long storage life; it must be trowellable so the mechanic can spread it easily on the tiled surface; the excess must be easily removable from the surface without the aid of harmful cleaning fluids; it must retain its position in the final joint without sagging, pinholing or shrinking; the time required to effect proper installation should be reasonable; and the grouted tile in final form must have certain desirable properties such as hardness, stainresistance, water impermeability, chemical resistance, acceptable color and durability.

Final performance properties are invariably sacrificed, according to current formulation practices, in order to achieve ease of application for the ceramic tile grout. Thus, the consumer is unfortunately denied the optimum performance of which grouting materials are capable. The present invention is intended to remedy that condition.

SUMMARY OF THE INVENTION Accordingly, this invention is concerned with an improved method of grouting tile which permits the tile installer or tile mechanic to beneficially modify an already trowelled ceramic tile grout composition by applying a property-improving material.

The typical procedure for grouting tile comprises the following steps:

a. trowellingthe grouting composition on a substrate and into the joints between the tile, said tile placed on said substrate;

b. removing excess grout from the tile faces;

c. washing the tile surface and shaping the joints to the desired configuration; and

d. cleaning the tile once the tile face is dry.

The materials disclosed herein are applied any time after step (a) in the form of a solution, partial solution, suspension dispersion, emulsion, etc. and are usually administered as a spray. Whenever possible, a solution applied as a liquid by means of a spray gun is preferred. If the material itself is a liquid, it is also within the teachings of this invention to apply it directly without the assistance of a diluent or solvent.

A principal advantage of the hereindisclosed process is that dramatic changes can be made in rheology of a grout after it is placed between tiles. In most if not all instances, it is unreasonable to incorporate the property-improving materials into the grout prior to trowelling. The reason is that properties desirable for trowelling are different from those desirable in the washing and shaping stages. In addition, storage life of the canned grout would be nil with some of the materials found beneficial to washing and clean-up if they were in the original formulation. However, once the grout has been trowelled and the usual initial stages of grouting have occurred, certain damaging reactions can be tolerated or minimized. More importantly, the materials can then be applied to provide unexpected and unusual beneficial results. In large scale commercial applications, the hereindisclosed novel method speeds up the grouting operation by as much as 25 percent. This is a very important consideration when trying to minimize expensive labor costs.

Although the exact mechanism in which these property-improving materials function is not fully understood at the present time, it is known that they act to accomplish one or both of the following:

I. firming the grout sufficiently so that when the washing or cleaning step is performed, the grouting composition is not undesirably removed or wiped away, and/or 2. forming a dustable haze which is easily removed. The usual technique is to wipe hard necessitating a difficult physical manipulation or by rewetting and then sponging with, for example, a wet cloth.

The type of grouting compositions which are subject to improvement by the hereindisclosed process include (I) grout compositions containing film-forming, water resistant polymers such as polymer emulsions having a solids content of at least 40 percent capable of coalescing upon the loss of water from the grouting composition; (II) grout compositions containing waterdispersible, room temperature, cross-linkable polymers combined with a water-insoluble filler; (III) Latex- Portland cement grouts and mortars; and (IV) nonaqueous hardened epoxy grouts.

Depending on the grouting composition used, particular property-improving materials will be utilized. However, in many instances, certain materials can be efiectively used for all types of grouting formulations,

whereas with others, only one type of formulation may be effectively treated.

Moreover, it is possible and within the purview of this invention to combine more than one of the hereindisclosed property improving materials. Of course, a restriction may be imposed on the physical nature of the mixture. For instance, a fatty acid will not dissolve in an aqueous solution. In those instances, the problem is easily solved by applying two separate formulations one right after the other or working with emulsions of the immiscible materials.

The following is a tabulation of the effective property improving materials of this invention together with the type of grouting formulation which is effectively treated by those materials:

Property Improving Material 1. Aqueous solution of a polyvalent metal salt or Nl-LCI Grouting Formulation Types I and I] described above Types I and II described above Group II metal hydroxide Cross-linking catalyst Hygroscopic agent coalescing accelerator 7. Water-insoluble fatty acid having6-20 carbons 8. Antifoaming agent 9. Wetting inhibitor Types I, II and III Type IV The amount of material sprayed onto the trowelled tiles will be determined, for the most part, subjectively.

The mechanic will spray a sufficient amount of cover the entire area which is to be treated.

DETAILED DESCRIPTION OF THE INVENTION Examples of the types of grout compositions which are advantageously treated by the process of this invention include:

A. An aqueous mortar composition having a viscosity in the range of 10,000 cps to 4,000,000 cps* The Brookfield helipath viscosity when measured at 2.5 rpm.) comprising a filmforming, water resistant polymer and a water-insoluble filler.

B. Latex-Portland cement type grouts.

C. Nonaqueous epoxy grouts.

A highly preferred embodiment of type A relates to those wherein said polymer, in the form of a water resistant polymer emulsion having a solids content of at least 40 percent, is capable of coalescing upon the loss of water from the grouting composition. Although the mechanism by which the aforesaid coalescence takes place is not fully understood, it is distinguishable from a cross-linking mechanism as described hereinafter. It is known, however, that as the grout loses water and then hardens by coalescence of the polymer emulsion particles, there is formed a grout, which is substantially more stain resistant than ordinary Portland cement type grouts.

The improved grouting compositions which incorporate these coalescent-type polymers, usually as aqueous emulsions, have a viscosity of 50,000 to 4,000,000 cps, a total solids content to 88 percent and a volatile component content of from 8 to 20 percent which comprises an admixture of a water-resistant polymer emulsion, having a solids content of at least 40 percent with the maximum content not in excess of about 75 percent and a water insoluble filler.

Another highly preferred embodiment of the aforedescribed compositions are those in which said polymer is a film-forming, water dispersible, room temperature cross-linkable polymer and the cross-linking process is assisted by the addition of a cross-linking agent or a catalyst. When an acidic catalyst is utilized, it is further preferred to include an activating agent.

Preferred amounts of each component are as follows: It is understood, however, that components A, B and F are essential components whereas the inclusion of C, D

and E are preferred embodiments.

Water-dispersible, cross-linkable polymer B. Wnter-insolublc filler C. Acidic catalyst D. Activating agent E. Cross-linking agent 2-1 6% by weight 50-90% by weight 0.03-2.0% by weight catalytic amounts an amount sufficient to permit substantial cross-linking (at least a stoichiometric equivalent amount) F. Water 8-1596 by weight gerald, mailed to the U.S. Pat. Office on Mar. 12, 1971, all having a common assignee.

Latex-Portland cement type grouts designated as 11 above are commonly used and known in the trade and consist of a mixture of Portland cement, polymer emulsion and mirror organic and inorganic additives.

Nonaqueous epoxy grouts are suitably described in U.S. Pat. Nos. 3,140,556, 3,183,198, 3,209,500, 3,212,946, 3,287,302, 3,311,515, 3,348,988, 3,396,138, 3,396,140 and 3,396,141.

By the term method of grouting tile," is meant the art recognized procedure for setting and grouting tile. In grouting, an assembly containing a plurality of ceramic tile in edge to edge relationship with spaces between the tiles is prepared and spaces between the tile filled with the compositions of this invention. When used to set and grout ceramic tile, the compositions form a hard, adherent, chemically resistant bond between the backs of said ceramic tile and the substrate.

Normal grouting comprises the steps of: l. trowelling the grout on the wall and into the joints between the tiles;

2. removing excess grout from the tile faces; 3. washing the tile surfaces and shaping the joints as desired with a sponge or similar soft pad; and

4. wiping the tile clean with a dry cloth or similar material.

The process improvement of this invention is concerned with the application of a property improving material to the grout which has been trowelled so that the resulting product is easier to handle during installation or demonstrates final performance properties above those of the original grout or both.

Although the manner in which the propertyimproving material is applied is not critical, it is preferred to spray a liquid onto the areas tobe treated making certain that the selected areas are completely covered.

The application can be effected any time after step (1) and prior to step (4) shown above.

The particular property improving materials can be categorized into groups as follows:

1. Aqueous solution of a polyvalent metal salt or NI-I Cl 2. Group 11 metal hydroxide 3. Tri-n-butyl phosphate, tall oil fatty acid, acetone, methyl ethyl ketone, glycerin, mineral oil, mineral spirits and mixtures thereof 4. Cross-linking agent or catalyst 5. l-lygroscopic agent 6. Coalescing accelerator 7. Water-insoluble fatty acid having 6-20 carbons 8. Antifoaming agent 9. Wetting inhibitor Regarding group (1), any polyvalent metal salt can be used, preferably derived from a metal of Groups I1 and Ill. Illustrative salts include calcium chloride, magnesium chloride and aluminum chloride. It is found that ammonium chloride is highly effective and is included within this category. A preferred concentration is from percent by Group (3) includes those substances shown. Since these substances are liquids, it is possible and possibly preferrable to administer them directly without incorporating them into a diluent or solvent. However, should a more fluid material be desired, any unreactive diluent may be added in typically used amounts to form a solution or emulsion which may then be applied.

Group (4) consists of cross-linking agents or catalysts. The particular catalyst or cross-linking agent utilized depends on the particular polymer in the system. For instance, to cross-link an epoxy resin, a crosslinking agent or hardening agent is preferred. Any cross-linking agent known in the art of polymerization is contemplated herein the only requisite is that it is capable of causing interaction between the functional groups on the polymer chains to permit the formation of a chemical bond.

In the situation where a catalyst is used to assist in the cross-linking process, the catalyst material is preferably an acidic catalyst and, in particular, inorganic and organic salts, organic acids and amine acid-addition salts. Specific examples include ammonium chloride, magnesium chloride, ammonium sulfate, ammonium bromide, ammonium thiocyanate, dichloroacetic acid, ptoluene sulfonic acid, citric acid, oxalic acid, sulfamic acid and 2-methyl-2-aminopropanol-l-hydrochloride. When the catalyst is an acidic catalyst of the type just described, it is sometimes desirable to include an activating agent to accelerate setting. A typical activating agent is formaldehyde; however, those known in the art of polymerization are within the purview of this invention. The amount of said activating agent will generally be in catalytic quantities.

Group (5) consists of hygroscopic agents. illustrative examples include: glycerin, calcium chloride, amines, urea, certain nitrates, etc. These substances comprise any material known 'in this particular field of study which retain or take up moisture.

Group (6) refers to coalescing accelerators. Typical examples are: butyl acetate, tri-n-butyl phosphate, acetone, certain divalent metal ions like calcium, magnesium, strong acids or strong bases and polyacrylic acid.

Group (7) comprises water-insoluble fatty acids having 6 to carbon atoms. A typical example of such an acid is tall oil fatty acid.

Group (8) consists of antifoaming agents such as trin-butyl phosphate, fatty acids, waxes, oils, etc. This group of substances contemplates any antifoaming agent known in this particular art.

Group (9) comprises wetting inhibitors such as tri-nbutyl phosphate when used on epoxy grout.

It has been indicated that each type can be used separately or in combination. Furthermore, the particular material chosen will depend on the grouting composition to be improved, adjusted or frustrated.

This invention facilitates automatic or machine grouting of ceramic tile. it is common now for the craftsman to get sheets of tiles together by flexible tabs or hinges. This reduces labor over setting one at a time. Machine grouting can further reduce labor. The property-improving material almost immediately firms up or flocculates the freshly affixed grout enabling the ma chining to almost immediately clean up and finish the grouting application.

EXAMPLE l Part A A polymer emulsion based grout on the following formula was applied to the surface of glazed wall tile set in a common ceramic tile adhesive on a gypsum wallboard wall:

Acrylic aq. emulsion (AC-33) 20.03 grams Ethylene glycol 2.82 grams TiO 3.17 grams Potassium tripolyphosphate 0.10 grams Anti-foaming agent 0.12 grams Limestone 5 micron part. size) l9.50 grams Silica (325 mesh) 21.30 grams Thickener (Carbopol 934) 0.01 grams Alumina trihydrate 27.72 grams Spherical glass (44-74 micron part. size) 5.00 grams Phenylmercurial fungicide 0.23 grams AC-33 is an acrylic latex polymer emulsion based on a major amount of ethyl acrylate and a minor amount of methyl methacrylate in proportions to provide a glass transition temperature of 12 C. sold commercially by Rohm and Haas.

The grout was spread over the entire tile area using a smooth rubber trowel and properly forced into the vertical and horizontal joints between the tile. After the joints were filled, the excess grout was removed using the edge of the trowel as a squeegee. After a short drying period, the remaining grout film and excess material filling the joints was wetted with a sponge and water, and the wall surface scrubbed lightly to loosen and remove the excess grout. Extreme care was taken to avoid too much water which would run down the vertical joints between tile and wash away grout that should remain. The sponge was used to wet polish the tile surface and dress the joints to a smooth finish and even contour. When the wall looked clean, sponging was stopped and the wall left to dry before final cleanup. As the wall dried, a haze formed over the tile surfaces. A dry cloth polishing rag was used to wipe off the dry haze. It was handled carefully and the haze came away, but took much work. The haze was hard on the tile by the time the last half of the wall was being worked and the wall had to be rewetted with a sponge to soften the haze.

The finished wall looked fine, but on close inspection it could be seen that vertical grout joints were deeper than ideal, a condition called washed-out by the trade and the horizontal joints had creases in their center line in many instances. The whole operation took 25 minutes of working time and was tiring during the difficult polishing stages.

Part B An identical wall surface and identical grout were used to duplicate the experience described in Part A of this example, except that the method of this invention was used to apply a 6 percent solution of calcium chloride in water to the wall at a critical time.

After the grout was spread on the wall and forced into the joints, the wall was squeegeed as before. At this point in the operation, the solution of calcium chloride was sprayed on the wall in sufiicient quantity to just wet it all without it running down the wall surface. Immediately after the spraying, the sponging and dressing of the joints was done. it was obvious that the grout in joints was firm and not easily washed away by excess water, so much less care and more speed could be used.

When the cleaning was done in the normal way, it was found that the haze that formed on the tile easily dusted away with the dry cloth. In fact, a small arealeft overnight dusted away the next morning as easily as the day before.

The finished wall looked very good. Vertical joints were full as desired and the horizontal joints were smooth and even without creases. The whole operation took only 20 minutes, a savings of 20 percent of the time and, as noted, resulted in a superior finished job.

In this example the effects of the sprayed-on solution were l firming of the grout in the joint which allowed faster washing and dressing and (2) some efiect on the dried haze which made it easy to remove in a simple manner.

it should be noted that an attempt to add calcium chloride directly to the grout before it was applied to the wall caused it to thicken so that it could not be trowelled and overnight it became hard in the can.

EXAMPLE I] Other chemicals were checked for their ability to produce either of the beneficial effects on the polymer emulsion grout described in Example 1.

Mixture of 6% aluminum chloride and 6% magnesium chlo ride These results illustrate the value of the new method and its versatility.

good firming dusting improved effect up to 72 hrs.

EXAMPLE III An epoxy grout of the water cleanable type described in U.S. Pat. No. 3,212,946 was used to grout ceramic wall tile. The procedure is similar to that of Example I except that the grout residue on the surface of the tile after trowelling it on the tile surface and into the joints is not so easily dispersed in water. Considerable scrubbing with the sponge is required to dislodge the sticky grout from the tile. A constituent of the nonaqueous grout, however, will emulsify in water and then act as an emulsifier for the rest of the system so that complete removal of the excess grout is eventually effected. During the process, considerable foam is generated, which is undesirable, and the epoxy resin resists separation from the tile surface. When cleaning was finally complete, bubbles of foam have to be removed or broken from the surface of the grout in the joints between tile, and the labor of the operation is considerable.

In a second attempt of the same grouting operation according to the method of this invention, tri-n-butyl phosphate was sprayed lightly in the panel after the squeegee operation. Subsequent washing with water was much easier mainly because of the substantial reduction of foam during the scrubbing operation but also because the tri-n-butyl phosphate appears to lift the epoxy resin away from the tile surface interfering with the wetting of the tile by the epoxy resin, allowing faster emulsification of it and generally easier clean-up.

Tall oil fatty acid can be substituted for tri-n-butyl phosphate and equivalent results are obtained.

EXAMPLE IV Tile grouts made using a dry Portland cement based composition and a liquid Latex additive give good performance properties but are diflicult to install and clean-up. They wash out of the joints easily with excess wash water and the residue on the tile surface is so difficult to remove in the final dry polishing stage that it often has to be rewetted. However, when a solution of 2% percent of polyacrylic acid, molecular weight of 16,000 to 20,000, in water, was sprayed on the wall after the grout was applied and squeegeed, washing went much faster with less washing out; a cleaner wall surface resulted after washing; and the haze that formed dusted away effortlessly a great improvement.

What is claimed is:

1. In a method of grouting tile which comprises the steps of:

a. trowelling a grouting composition consisting of an aqueous mortar composition having a viscosity in the range of 10,000 cps to 4,000,000 cps which comprises a film-forming water resistant polymer selected from the group consisting of water resistant polymer emulsions having a solids content of at least 40 percent capable of coalescing upon the loss of water from the grouting composition and water-dispersible, room temperature cross-linkable polymers, and a water insoluble filler; on a tiled substrate and into the joints between the tile, said tile placed on said substrate;

. removing excess grout from the tile faces;

0. washing the tile surface and shaping the joints to the desired configuration; and

. cleaning the tile once the tile face is dry; the improvement which comprises an additional step of applying to the grout after trowelling a material consisting of an aqueous solution of a polyvalent metal salt or ammonium chloride having a concentration of from 1 percent by weight to saturation applied as a thin film of liquid which beneficially changes the rheology of the grout subsequent to its placement between tiles.

2. The method claim 1 wherein said polyvalent metal salt is selected from the group consisting of calcium chloride, magnesium chloride and aluminum chloride.

3. The method of claim 2 wherein said metal salt is a 3 to 9 percent by weight aqueous solution of calcium chloride.

4. The method of claim 1 wherein said beneficial changes comprise a sufficient firming of the grout so that when the washing or cleaning step is performed, the grouting composition is not undesirably removed and/or the forming of a dustable haze which is easily removed.

5. The method of claim 1 wherein said polymer is a cross-linltable polymer and said cross-linking is promoted by a cross-linking agent or catalyst.

6. The method of claim 5 wherein said catalyst or cross-linking agent is added in conjunction with and during the application of said property improving material.

* I I i i 

1. In a method of grouting tile which comprises the steps of: a. trowelling a grouting composition consisting of an aqueous mortar composition having a viscosity in the range of 10,000 cps to 4,000,000 cps which comprises a film-forming water resistant polymer selected from the group consisting of water resistant polymer emulsions having a solids content of at least 40 percent capable of coalescing upon the loss of water from the grouting composition and water-dispersible, room temperature cross-linkable polymers, and a water insoluble filler; on a tiled substrate and into the joints between the tile, said tile placed on said substrate; b. removing excess grout from the tile faces; c. washing the tile surface and shaping the joints to the desired configuration; and d. cleaning the tile once the tile face is dry; the improvement which comprises an additional step of applying to the grout after trowelling a material consisting of an aqueous solution of a polyvalent metal salt or ammonium chloride having a concentration of from 1 percent by weight to saturation applied as a thin film of liquid which beneficially changes the rheology of the grout subsequent to its placement between tiles.
 2. The method claim 1 wherein said polyvalent metal salt is selected from the group consisting of calcium chloride, magnesium chloride and aluminum chloride.
 3. The method of claim 2 wherein said metal salt is a 3 to 9 percent by weight aqueous solution of calcium chloride.
 4. The method of claim 1 wherein said beneficial changes comprise a sufficient firming of the grout so that when the washing or cleaning step is performed, the grouting composition is not undesirably removed and/or the forming of a dustable haze which is easily removed.
 5. The method of claim 1 wherein said polymer is a cross-linkable polymer and said cross-linking is promoted by a cross-linking agent or catalyst.
 6. The method of claim 5 wherein said catalyst or cross-linking agent is added in conjunction with and during the application of said property improving material. 